US5282125A

US5282125A - Power generation system with soft-start circuit

Info

Publication number: US5282125A
Application number: US07/882,391
Authority: US
Inventors: P. John Dhyanchand; Chai-Nam Ng; Sunil Patel; Vietson M. Nguyen
Original assignee: Sundstrand Corp
Current assignee: Sundstrand Corp
Priority date: 1992-05-13
Filing date: 1992-05-13
Publication date: 1994-01-25
Anticipated expiration: 2012-05-13

Abstract

Control pulses having a first frequency are supplied to the switches of an inverter by a controller. During initial operation of the inverter, however, a softstart circuit supplied pulses to the inverter switches of the inverter wherein the soft-start pulses have a second frequency. The second frequency is constant and higher than the first frequency.

Description

TECHNICAL FIELD

The present invention is directed to a power generation system for an aircraft having a stepped-waveform inverter of the type used to generate AC power from DC power and a soft-start circuit to reduce undesirable inrush currents during start-up of the inverter.

BACKGROUND ART

Power generation systems, such as variable-speed, constant-frequency (VSCF) power conversion systems, are commonly used to generate AC and DC power. In one such application, variable-frequency AC power may be produced by a brushless, synchronous generator driven by a jet engine. The variable-frequency AC power is converted to DC power by an AC/DC converter, such as a rectifier bridge. An inverter is coupled to the AC/DC converter to transform the DC power into constant-frequency AC power, which is then filtered by a filter. The filtered AC output is then provided to an AC load bus which supplies power to various loads.

The inverter used in VSCF systems may be of the stepped-waveform type. An inverter of this type is disclosed in U.S. Pat. No. 3,775,662 to Compoly et al. Such a stepped-waveform inverter generates an output having a stepped shape that generally approximates a sine wave. The purpose of approximating a sine wave is to reduce the size of the filters, provided at the output of the inverter, that are used to remove unwanted harmonics.

Power conversion systems often rely upon saturable reactors such as inductive-type filters or transformers. When the power conversion system is first initiated to begin the power conversion process, the sudden application of power to the saturable reactor may cause it to saturate providing little impedance to current. This current faced with little impedance can become quite large and can possibly damage elements of the power conversion system such as its inverter switches. In order to prevent such damage, it is desired to limit or inhibit this inrush current.

SUMMARY OF THE INVENTION

The present invention is directed to an arrangement for limiting inrush current. Accordingly, an inverter system is provided having inverter switches for inverting DC to AC. A soft-start pulse supply circuit supplies soft-start pulses to the inverter switches to begin the inverter process. After a time, a controller takes over and supplies normal control pulses to the inverter switches. The soft-start pulses have a higher frequency than the normal control pulses.

The soft-start pulses may have a substantially constant duty cycle and amplitude and the frequency of the soft-start pulses also may be substantially constant.

An excitation circuit may be provided to supply the soft-start pulses. The excitation circuit has a monostable multivibrator for providing a timing pulse initiated at start-up of the inverter system for controlling the number of soft-start pulses supplied to the inverter switches.

The inverter switches may be used to energize the primary windings of two transformers, the second windings of which are interconnected so that voltages induced therein are added.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and other advantages of the present invention will become more apparent from a detailed consideration of the invention when taken in conjunction with the drawings in which:

FIG. 1 is a block diagram of a VSCF power conversion system in which the present invention can be used;

FIG. 2 is a block diagram of the inverter of FIG. 1;

FIG. 3 is a circuit diagram of one pair of subinverters and their associated transformers of the inverter of FIG. 2;

FIG. 4 is a circuit diagram of one of the activation circuits of FIG. 2;

FIG. 5 illustrates a first phase relationship of a number of waveforms generated by the inverter and a waveform produced by the summation of those waveforms;

FIG. 6 illustrates a second phase relationship of a number of waveforms generated by the inverter and a waveform produced by the summation of those waveforms;

FIG. 7 illustrates a third phase relationship of a number of waveforms generated by the inverter and a waveform produced by the summation of those waveforms;

FIG. 8 illustrates a fourth phase relationship of a number of waveforms generated by the inverter and a waveform produced by the summation of those waveforms;

FIGS. 9a-9c are vector diagrams illustrating a first mode of operation of the inverter of the invention;

FIGS. 10a-10c are vector diagrams illustrating a second mode of operation of the inverter of the invention;

FIG. 11 illustrates various waveforms relating to the operation of the phase angle control circuit of FIG. 2;

FIG. 12 is a circuit diagram of the phase angle control circuit shown schematically in FIG. 2;

FIG. 13 is a circuit diagram of the output sensing circuit shown schematically in FIG. 2;

FIG. 14 is a graph of two voltage signals used in the phase angle control circuit to control the phase relationship of the waveforms generated by the inverter; and

FIG. 15 is an illustration of a number of waveforms generated during operation of the activation circuit shown in FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A block diagram of a preferred embodiment of a VSCF power conversion system 10 incorporating the present invention is shown in FIG. 1. The power conversion system 10 includes a prime mover 12 coupled to a generator 14 for generating variable-frequency AC power. An AC/DC converter 16 is coupled to the generator 14 for converting the variable-frequency AC power into DC power. The DC output of the AC/DC converter 16 is supplied to various DC loads via a pair of lines 20a, 20b. A second pair of

lines

22a, 22b provides the DC to an inverter 24, which generates three-phase, constant-frequency AC power from this DC. The inverter 24 is coupled to a filter 26 via three

output lines

28a, 28b, 28c, each of which supplies a respective phase of the constant-frequency AC output to the filter 26. The output of the filter 26 is provided via lines 29 to a three-phase AC load bus which supplies AC power to various AC loads

A block diagram of the inverter 24 is shown in FIG. 2. The inverter 24 includes three

subinverter pairs

30, 32, 34, although any number of subinverters may be used. Each of the

subinverter pairs

30, 32, 34 is coupled to a

respective transformer pair

31, 33, 35. The

output lines

28a, 28b, 28c interconnect each of the

transformer pairs

31, 33, 35, and the transformer pair 35 is connected to a neutral line 28d. Each of the

subinverter pairs

30, 32, 34 is controlled by a respective activation circuit 40a-c.

A regulator circuit for regulating the voltage on the

transformer output lines

28a, 28b, 28c is shown to comprise an output sensing circuit 50 and a phase angle control circuit 52. The output sensing circuit 50 senses the current on the three

transformer output lines

28a, 28b, 28c via three

lines

56a, 56b, 56c, and the sensing circuit 50 senses the voltage on the three

output lines

28a, 28b, 28c via three

lines

58a, 58b, 58c. The output sensing circuit 50 generates a phase control signal, φ_c, having a magnitude based on both the voltage and current sensed on the lines 28a-c and provides the φ_c signal to the phase control circuit 52 via a line 60. Based on the magnitude of the φ_c signal, the phase angle control circuit 52 causes the phase angles between the various waveforms generated by the three

subinverter pairs

30, 32, 34 to be varied. As a result of the control of the phase angles, the magnitude of the voltage on the

transformer output lines

28a, 28b, 28c is regulated.

Alternatively, instead of sensing the AC output on the lines 28a-c, the regulator circuit could sense the AC output on the lines 29 after the AC output is filtered by the filter 26.

The phase angle control circuit 52 varies the magnitude of the phase angles by generating a pair of reset signals, RES2 and RES3, based upon the magnitude of the phase control signal φ_c and a pair of reference signals, REF1 and REF2. The REF1 and REF2 signals are transmitted to the phase angle control circuit 52 from the first and

second activation circuits

40a, 40b via a pair of

lines

66, 68, respectively. The RES2 and RES3 signals are transmitted from the phase angle control circuit 52 to the second and

third activation circuits

40b, 40c via a pair of

lines

70, 72, respectively. As described in more detail below, the RES2 signal controls the phase angle between the waveforms generated by the first subinverter pair 30 and the waveforms generated by the second subinverter pair 32, and the RES3 signal controls the phase angle between the waveforms generated by the second subinverter pair 32 and the waveforms generated by the third subinverter pair 34.

The first subinverter pair 30 and the first transformer pair 31 are shown in FIG. 3. The first subinverter pair 30 includes two

subinverters

30a, 30b, and the first transformer pair 31 includes two three-phase transformers 31a, 31b.

The subinverter 30a includes six transistor switches 82a-c, 84a-c, each of which has a diode connected across it. The subinverter 30a is connected to three wye-connected primary windings 80a-c of the transformer 31a which are controlled by the three pairs of switches 82a-c, 84a-c, although these windings alternatively may be delta connected. The upper terminal of the winding 80a is connected to the junction of the switches 82a, 84a; the upper terminal of the winding 80b is connected to the junction of the

switches

82b, 84b; and the upper terminal of the winding 80c is connected to the junction of the

switches

82c, 84c. The bottom terminals of windings 80a, 80b, 80c are connected together. The primary windings 80a-c of the transformer 31a are inductively coupled to three secondary windings 90a-c, respectively.

During operation of the subinverter 30a, exactly one of the two switches in each vertical branch is conducting. In particular, one of the two switches 82a, 84a is conducting and the other is off; one of the

switches

82b, 84b is conducting and the other is off; and one of the

switches

82c, 84c is conducting and the other is off. The switches 82a-c and 84a-c are switched in a conventional manner to generate the waveform 220 in FIG. 5 on each of the three wye-connected windings 80a-c, each of the three waveforms differing in phase by 120°. Because the windings 80a-c are wye connected, the waveform 220 has five possible amplitudes at any point in time, +A, +A/2, 0, -A/2, and -A, where A is the maximum amplitude.

The subinverter 30b includes six transistor switches 94a-c, 96a-c, each of which has a diode connected across it. The subinverter 30b is connected to three delta-connected primary windings 92a-c of the transformer 31b which are controlled by the three pairs of switches 94a-c, 96a-c, although these windings may be alternatively wye connected. The upper terminal of the winding 92a is connected to the junction of the

switches

94a, 96a and to the bottom terminal of winding 92c; the upper terminal of the winding 92b is connected to the junction of the

switches

94b, 96b and to the bottom terminal of winding 92a; and the upper terminal of the winding 92c is connected to the junction of the

switches

94c, 96c and to the bottom terminal of winding 92b. The three delta-connected primary windings 92a-c are inductively coupled to three secondary windings 98a-c of the transformer 31b, respectively.

The switches 94a-c and 96a-c are switched in a manner similar to switches 82a-c and 84a-c to generate the waveform 222 in FIG. 5 on each of the three delta-connected windings 92a-c, each of the three waveforms 222 having a phase difference of 120°. Because the windings are delta connected, such a waveform has three possible amplitudes, +A, 0, and -A, where A is the maximum amplitude.

While the switches 82a-c, 84a-c, 94a-c, 96a-c are shown to be transistors, other types of switches may be used, such as thyristors or D'Arlington-connected transistor pairs.

The circuit diagrams for the second and third subinverter pairs 32, 34 and the second and third transformer pairs 33, 35 are identical to the one shown in FIG. 3 and are not shown separately for purposes of simplicity.

The activation of the twelve switches 82a-c, 84a-c, 94a-c, 96a-c in each of the subinverter pairs 30, 32, 34 is controlled by a respective one of the activation circuits 40a-c. Since the three activation circuits 40a-c are substantially identical, only one is shown. Referring to FIG. 4, the activation circuit 40 includes three four-bit counters 110, 112, 114 connected to an EPROM 116 which in turn is connected to a driver circuit 118. The

counters

110, 112, 114 are driven by a clock signal, CLK, generated by a main controller (not shown). The carry output of the counter 110 is input to the counter 112 via a line 111, and the carry output of the counter 112 is input to the counter 114 via a line 113. Upon each pulse of the CLK signal, the 10-bit output of the

counters

110, 112, 114 is incremented by one. This 10-bit output is used as an address to address the EPROM 116.

The EPROM 116 has a six-bit binary code stored in each of its address locations. The six binary bits control the activation of the 12 switches in one of the subinverters. In particular, one bit of the six-bit binary code is output on the line 122 to the driver 118, which generates an uncomplemented switching signal on a line 124 and a complemented switching signal on a line 126. The line 124 is connected to the base of one transistor in one vertical branch of one of the subinverters, such as switch 82a, and the line 126 is connected to the base of the other switch in the vertical branch, such as switch 84a.

The remaining five bits of the six-bit binary code are output On the

lines

130, 132, 134, 136, 138, respectively, to the driver circuit 118, which generates on its outputs a pair of complemented driving signals for each of the five binary signals. These driving signals are supplied to the remaining switches of the subinverter.

During operation of each of the activation circuits 40, as the CLK signal periodically increments the

counters

110, 112, 114, the six bits of the binary code are periodically output from the EPROM 116 via lines 122, 130-138 to the driver 118, and the 12 switches of each corresponding subinverter pair 30a30b, 32a/32b, and 34a/34b are controlled to generate each corresponding pair of the waveforms 220/222, 224/226, and 228/230 shown in FIG. 5 on the primary windings of the corresponding transformers 31a/31b, 33a/33b, and 35a/35b.

The EPROM 116 generates a reference signal, REF, on a line 142. As described in more detail below, the REF signal is used as a phase reference signal.

A reset signal, RES, may be input to the

counters

110, 112, 114 via a line 140. When the RES signal is activated, the

counters

110, 112, 114 are reset, thus providing a 10-bit address to the EPROM 116 equal to zero. The contents of each EPROM in the three activation circuits 40a-c are identical. If each of the EPROMs is given the same sequence of addresses, the resulting waveforms generated by the subinverters would be identical and thus have zero phase angle. Accordingly, the time of reset of the

counters

110, 112, 114 of an activation circuit determines the phase angle between the waveforms generated by that activation circuit and the waveforms generated by the other two activation circuits.

When the activation circuit 40 of FIG. 4 is used for the activation circuit 40a shown in FIG. 2, the REF line 142 of FIG. 4 is connected to the REF1 line 66 of FIG. 2, and the RES line 140 of FIG. 4 is not used. When the activation circuit 40 of FIG. 4 is used for the activation circuit 42b, the REF line 142 of FIG. 4 is connected to the REF2 line 68 of FIG. 2, and the RES line 140 of FIG. 4 is connected to the RES2 line 70 of FIG. 2. When the activation circuit 40 of FIG. 4 is used for the activation circuit 40c, the RES line 140 of FIG. 4 is connected to the RES3 line 72 of FIG. 2, and the REF line 142 of FIG. 4 is not used.

The activation circuit 40 has a soft-start circuit 150 which, as described in more detail below, is used during a start-up period of the inverter 24 to reduce undesirable inrush currents.

Stepped-waveform inverters having six subinverters as shown in FIG. 2 are referred to as 36-step inverters.

Referring to FIG. 5, the waveforms generated by one phase of the

subinverters

30a, 30b, 32a, 32b, 34a, 34b in the corresponding phase of the primary windings of the transformers 31a, 31b, 33a, 33b, 35a, 35b are shown. The summing transformer output waveform 240 shown in the bottom portion of FIG. 5 is generated on each of the three

transformer output lines

28a, 28b, 28c, each of the three waveforms 240 being 120° apart. The waveform 240 represents the summation of the

waveforms

220, 222, 224, 226, 228, 230.

The inverter 24 of the present invention has two modes of operation during steady-state operation. A first mode of operation is used when the current on the output lines 28a-c of the summing transformer is below a predetermined threshold. A second mode of operation is used when the output current is above the predetermined threshold.

In the first mode of operation, the phase angle between the waveforms generated by the first subinverter pair 30 and the waveforms generated by the second subinverter pair 32 is held constant, preferably 15°, and the phase angle between the waveforms generated by the second subinverter pair 32 and waveforms generated by the third subinverter pair 34 is varied, depending upon the output voltage sensed on the transformer output lines 28a-c.

The waveforms shown in FIGS. 5 and 6 illustrate the first mode of operation. It should be noted that the first

subinverter pair waveforms

220, 222 and the second

subinverter pair waveforms

224, 226 of both FIGS. 5 and 6 have a fixed phase angle of 15°. However, the phase angle between the second

subinverter pair waveforms

224, 226 and the third

subinverter pair waveforms

228, 230 is 0° in FIG. 5 and 60° in FIG. 6. By controlling the phase angle between the second and third subinverter pair waveforms, the resultant output voltage may be regulated. For example, the waveform 240 of FIG. 5 has a peak positive amplitude of +6A and a peak negative amplitude of -6A, whereas the output voltage waveform 240 of FIG. 6 has a peak positive amplitude of +51/2A and a peak negative amplitude of -51/2A.

Referring to FIGS. 9a-9c, the vector diagrams in those figures illustrate the first mode of operation. The vector V₁ represents the first

subinverter pair waveforms

220, 222; the vector V₂ represents the second

subinverter pair waveforms

224, 226; and the vector V₃ represents the third

subinverter pair waveforms

228, 230. In each of FIGS. 9a-c, the phase angle between V₁ and V₂ is constant, at 15°. The phase angle between V₂ and V₃ may vary from a minimum phase angle of 0° as shown in FIG. 9a to a maximum phase angle of 120° as shown in FIG. 9c. In between the minimum and maximum phase angles, the phase angle may be any variable angle α as shown in FIG. 9b. The vector positions shown in FIGS. 9a and 9c represent the extreme phase angles of the first mode of operation, and during normal operation the phase angles will be as shown in FIG. 9b.

In the second mode of operation, the phase angle between the waveforms generated by the first and second subinverter pairs is a variable angle between 15° and 120°, while the phase angle between the waveforms generated by the second and third subinverter pairs is held constant, preferably 120°. As a result, the voltage on the transformer output lines is gradually reduced to zero. The second mode of operation is used when the current on the output lines 28a-c is above the predetermined threshold.

The waveforms shown in FIGS. 7 and 8 illustrate the second mode of operation. In FIGS. 7 and 8, the third

subinverter pair waveforms

228, 230 lag the second

subinverter pair waveforms

224, 226 by a constant 120°. However, the phase angle between the first

subinverter pair waveforms

220, 222 and the second

subinverter pair waveforms

224, 226 is 45° in FIG. 7 and 120° in FIG. 8. The transformer output voltages, which are represented by the waveforms 240 in FIGS. 7 and 8, are gradually reduced to zero. In FIG. 7, the amplitude of the waveform 240 reaches a peak amplitude of +3A between 135° and 150° and -3A between 315° and 330°, and in FIG. 8 the waveform 240 has zero amplitude.

Now referring to FIGS. 10a-10c, the vector diagrams in those figures illustrate the second mode of operation. The vector V₁ represents the first

subinverter pair waveforms

220, 222; the vector V₂ represents the second

subinverter pair waveforms

224, 226; and the vector V₃ represents the third

subinverter pair waveforms

228, 230. In FIGS. 10a-10c, the phase angle between V₂ and V₃ is constant, at 120°. The phase angle between V₁ and V₂ may vary from a minimum phase angle of 15° as shown in FIG. 10a to a maximum phase angle of 120° as shown in FIG. 10c. In between the minimum and maximum phase angles, the phase angle may be any variable angle B as shown in FIG. 10b.

One manner of controlling the phase angles is illustrated in FIG. 11, which illustrates the control of the phase angle between the subinverter 32a waveform 224 and the subinverter 34a waveform 228. Referring to FIG. 11, the waveform 224 is shown in its phase relationship with respect to the REF2 signal. As can be seen, REF2 changes from zero to positive when waveform 224 transitions to a positive amplitude and from positive to zero when waveform 224 transitions to a negative amplitude. A ramp signal, RAMP, is generated based upon the magnitude of the REF2 signal. The rising edge of the REF2 signal corresponds to the beginning of the RAMP signal. When the REF2 signal is positive, the amplitude of the RAMP signal slowly increases. When the magnitude of the REF2 signal changes to zero, the magnitude of the RAMP signal quickly decreases to zero.

The RAMP signal is used to generate the RES3 signal based on a phase control signal φ_c3 generated from the phase control signal φ_c of FIG. 2. The magnitude of the φ_c3 signal varies, depending upon the magnitude of the current and voltage sensed on the

transformer output lines

28a, 28b, 28c. The relative values of the RAMP and φ_c3 signals are used to generate a comparison signal, COMP, having a positive amplitude when the value of the RAMP signal is greater than the value of the φ_c3 signal and a zero amplitude when the value of the RAMP signal is less than the value of the φ_c3 signal. The point of intersection of the rising portion of the RAMP signal and the φ_c3 signal determines the magnitude of the phase delay between the subinverter waveforms. This intersection point is shown as point 260 in FIG. 11.

At the intersection point 260, the COMP signal changes from zero to a positive amplitude. The rising edge of the COMP signal triggers the RES3 signal to become positive, or activated. When the RES3 signal is activated, it resets the counters associated with the third subinverter pair 34. As a result, the counters produce a zero 10-bit address, and the EPROM starts to generate the waveform 228. Thus, the time-occurrence of the rising edge of the RES3 signal controls the phase difference between the waveform 224 and the waveform 228. This phase difference is shown in FIG. 11 as Δφ.

It should be appreciated that the magnitude of the φ_c3 signal determines the magnitude of the phase delay Δφ. If the magnitude of φ_c3 is larger, the φ_c3 signal will intersect the RAMP signal later, thus causing a larger phase delay. If the magnitude of φ_c3 is smaller, the φ_c3 signal will intersect the RAMP signal earlier, thus causing a smaller phase delay.

The manner of varying the phase angle between the first subinverter pair waveforms and the second subinverter pair waveforms is similar to the manner described immediately above, except that the phase angle is between

waveforms

220 and 224, REF1 is used in place of REF2, and RES2 is generated instead of RES3.

The phase angle control circuit 52 for controlling the phase angles between the three subinverter pairs 30, 32, 34 is shown in FIG. 12. The REF1, REF2, and φ_c signals are input to the phase angle control circuit 52 via the

lines

66, 68, 60, respectively, and the circuit 52 generates the RES2 and RES3 signals on the

lines

70, 72, respectively. The circuit 52 includes a ramp generator comprising a comparator 302 having an inverting input which receives the REF1 signal and a noninverting input that receives a predetermined reference voltage. The ramp generator also includes a transistor 304, a capacitor 306, and a constant current source comprising an operational amplifier 308 and a transistor 310.

The capacitor 306 is slowly charged by the constant current source via the transistor 310 when the transistor 304 is nonconducting and is quickly discharged through the transistor 304 when the transistor 304 becomes conductive. The transistor 304 conducts when the value of the REF1 signal is less than the predetermined voltage provided at the noninverting input of the comparator 302. As a result, a ramp signal is produced on the line 312.

The ramp signal is input to the noninverting input of a comparator 314 via the line 312. The inverting input of the comparator 314 is supplied with a φ_c2 signal having a magnitude based upon the φ_c signal. The comparator 314 generates on a line 316 a comparison signal having a high output when the value of the ramp signal is greater than φ_c2 and a low output when the value of the ramp signal is less than the value of φ_c2. The comparison signal on line 316 is provided to a monostable multivibrator, or one-shot 318 comprising three inverters and a capacitor. The output of the one-shot 318 is the RES2 signal, which determines the phase angle between the waveforms of the first subinverter pair 30 and the waveforms of the second subinverter pair 32.

The RES3 signal is generated in a similar manner. A second ramp generator comprises a comparator 332 having an inverting input that receives the REF2 signal and a noninverting input that receives the reference voltage. The second ramp generator also includes a transistor 334, a capacitor 336, and a constant current source comprising an operational amplifier 338 and a transistor 340.

The capacitor 336 is slowly charged by the constant current source via the transistor 340 when the transistor 334 is not conducting and is quickly discharged through the transistor 334 when the transistor 334 conducts The transistor 334 conducts when the value of the REF2 signal is less than the predetermined voltage provided at the noninverting input of the comparator 332. As a result, a ramp signal is produced on the line 342.

The ramp signal is input to the noninverting input of a comparator 344 via the line 342. The inverting input of the comparator 344 is supplied with the φ_c3 signal. The comparator 344 generates on a line 346 a comparison signal having a high output when the value of the ramp signal is greater than φ_c3 and a low output when the value of the ramp signal is less than the value of φ_c3 The comparison signal on line 346 is provided to a one-shot 348 comprising three inverters and a capacitor. The output of the one-shot 348 is the RES3 signal which determines the phase angle between the waveforms of the second subinverter pair 32 and the waveforms of the third subinverter pair 34.

The magnitude of the φ_c2 and φ_c3 signals is determined by a third portion of the phase angle control circuit 52 shown in the bottom of FIG. 12, based upon the magnitude of the φ_c signal. The φ_c3 signal is generated by an operational amplifier 350 that acts as a voltage follower. Thus, the output of the amplifier 350 follows the magnitude of the φ_c signal. A zener diode 352 is connected to the output of the amplifier 350 and acts to limit the magnitude of the φ_c3 signal to a maximum predetermined value. This predetermined value is the voltage that causes a 120° phase angle difference between the second and third subinverter pair waveforms.

The φ_c2 signal is generated by an operational amplifier 354 that acts as an inverter. The φ_c signal is supplied to the noninverting input of the amplifier 354, while a predetermined voltage signal is supplied to its inverting input. The predetermined voltage is produced by an operational amplifier 356 having its noninverting input connected to a reference source 358.

The φ_c signal is generated by the output sensing circuit 50 based upon the current and voltage sensed on the transformer output lines 28a-c. The output sensing circuit 50 is shown in detail in FIG. 13. The output sensing circuit 50 includes a first portion shown at the bottom of FIG. 13 that generates a voltage based on the amount of current sensed in the

lines

56a, 56b, 56c. The three phases of output current, I.sub.φA, I.sub.φB, I.sub.φC, on the

lines

56a, 56b, 56c, respectively, are rectified by a half-wave rectifier circuit 360. The output of the half-wave rectifier circuit 360 is filtered by a smoothing capacitor 362 and then provided to the inverting input of a operational amplifier 364 used for scaling purposes. The output of the operational amplifier 364 is passed through a zener diode 366 which is coupled to the inverting input of an operational amplifier 368 that acts as an inverter. The operational amplifier 368 generates a negative voltage, -I_o, that is zero if the amount of current sensed in the

lines

56a, 56b, 56c is not above a predetermined threshold. The current threshold corresponds to twice the rated current for the power conversion system 10. If the current sensed is above the threshold, then the magnitude of -I_o is proportional to the amount of current over the threshold, or overcurrent. The -I_o signal is transmitted to a summing point 370 via a line 372.

The upper portion of the output sensing circuit 50 comprises three precision full-

wave rectifiers

390, 392, 394 coupled to receive the phase voltages, V.sub.φA, V.sub.φB, V.sub.φC on the

lines

58a, 58b, 58c, respectively. The rectified phase voltages are summed at the inverting input of an operational amplifier 400. The operational amplifier 400 generates a negative voltage at its output, -V_o, which has a magnitude that is proportional to the average output voltage sensed on the

lines

58a, 58b, 58c. The -V_o signal is transmitted to the summing point 370.

The summing point 370 is also connected to a circuit 402 that generates a predetermined reference voltage, V_ref. The V_ref voltage represents the desired voltage at which the transformer output lines 28a-c should be kept. At the summing point 370, the V_ref, and V_o, and -I_o signals are summed to produce an error signal, V_err, which equals V_ref -I_o -V_o. In normal operation, when the magnitude of the summing transformer output current is below the predetermined current threshold, the value of -I_o will be zero, and the error signal will equal V_ref -V_o. However, if the output current exceeds the threshold, then I_o will be a nonzero value, and it will effectively reduce the magnitude of the predetermined voltage, V_ref. If the overcurrent is large enough, the magnitude of I_o will become as large as V_ref, and the effective reference voltage, V_ref -I_o, will become zero. As a result, the actual voltage V_o will be reduced to zero. The amount of sensed current necessary to reduce the effective reference voltage to zero is three times the rated current for the system 10. Thus, when the current reaches three times the rated current, the output voltage on the lines 28a-c drops to zero.

The summed error voltage at the summing point 370 is input to the inverting input of an operational amplifier 404 which integrates the error. The amplifier 404 is coupled to an operational amplifier 406 that acts as a buffer and which produces the φ_c signal, Which ultimately determines the phase relationships of the waveforms generated by the three subinverter pairs 30, 32, 34.

Referring to FIG. 14, the magnitude of the phase control signals φ_c2 and φ_c3 is shown in the two modes of operation of the inverter 24 with respect to the magnitude of the φ_c signal. During the first mode, the φ_c2 signal has a constant voltage that produces a phase angle of 15° between the waveforms of the first subinverter pair 30 and the waveforms of the second subinverter pair 32. In this mode the φ_c3 signal has a voltage that gradually increases to cause a gradually increasing phase angle between the second and third subinverter pair waveforms, until it hits a peak voltage sufficient to cause a 120° phase angle.

During the second mode of operation, the voltage of the φ_c3 signal stays at its peak, and the voltage of the φ_c2 signal gradually increases until it reaches a maximum voltage sufficient to cause a phase angle of 120° between the waveforms of the first subinverter pair 30 and the waveforms of the second subinverter pair 32.

THE SOFT-START CIRCUIT

The soft-start circuit 150 shown in FIG. 4 is used to drive the subinverter switches 82, 84, 94, 96 at a relatively high frequency during a start-up mode of the inverter 24, prior to the steady-state mode of the inverter 24, to reduce undesirable inrush currents. FIG. 15 shows the waveforms on the designated conductors of FIG. 4.

The soft-start circuit 150, in FIG. 4, includes an oscillator 450 that supplies a relatively high frequency, 50% duty cycle signal, FIG. 15, to a monostable multivibrator, or one shot 452, via a line 454. The one shot 452, which has a relatively short activation time, generates an output signal on a line 456 having a frequency one-half that of the oscillator output and a duty cycle of approximately 70%. The output signals generated by the oscillator 450 on the line 454 and the one shot 452 on the line 456 are shown in FIG. 15.

The relatively high frequency signal generated by the one shot 452 is provided to one input of an AND gate 460 via the line 456. The other input of the AND gate 460 is provided with a logic signal on line 474 defining the duration of the start-up mode of operation. That signal is generated by a start signal that is provided to a one shot 470 via a line 472. The rising edge of the start signal defines the beginning of the inverter start-up period, and the end of the start-up period is determined by the falling edge of the signal generated by the one shot 470 on a first of its two output lines 474. The second output line 476 of the one shot is complemented with respect to its output on the line 474. The start-up signal on the line 472 and both outputs of the one shot 470 are shown in FIG. 15.

The AND gate 40 performs a logical "and" of the two signals provided on the

lines

456 and 474 and provides the result on its output line 480. The signal on the line 480, which is shown in FIG. 15, is identical to the relatively high frequency signal generated by the one shot 460 during the start-up period, but is zero outside the start-up period.

Some additional processing is performed on the signal 480. The purpose of the additional processing is to change the value of the signal 480 from logical "0" to a logical "1" after the completion of the start-up period. This additional processing is performed by an OR gate 484 coupled to an AND gate 486. The OR gate 484 has a first input connected to receive the signal 480 and a second input connected two receive the signal 476. The logical "or" of those two signals is provided by the OR gate 484 to a first input of the AND gate 486 via a line 488. The second input of the AND gate 486 is provided with the start signal via the line 472. The logical "and" of the

signals

472, 488 is provided from the AND gate 486 to a buffer 510 via a line 512. The signals on the

lines

488 and 512 are shown in FIG. 15.

The signal 512, which has a relatively high frequency during the start-up period and is logic "1" after the start-up period, is connected through buffer 510 to inputs of driver 118. Driver 118 performs a logical "and" function between the output of buffer 510 and each of the signals on

lines

122, 130, 132, 134, 136, 138. FIG. 15 shows how driver 118 performs this function using the signal on line 122 as an example. Driver 118 "ands" the soft-start pulses on line 512 with the control pulses on line 122. Accordingly, the signal on output 124 from driver 118 is comprised of the pulses on line 512 while the signal on line 122 is a logical "1." when the signal on line 122 switches to a logical "0," however, the soft-start pulses no longer appear on line 124 and line 124 is a logical "0." The next logical "1" on line 122 occurs after the soft-start pulses having ceased and the output from AND gate 486 remains at a logical "1." Accordingly, the control pulses on line 122 now appear on output 124 from driver 118.

While soft-start pulses appear on line 124, they are inverted and appear on line 126 as the complement of the pulses on line 124. Similarly, the pair of driver 118 outputs associated with line 130 also carry complemented and uncomplemented soft-start pulses as does the pair of driver 118 outputs associated with line 132 and so on. However, the number of soft-start pulses appearing on any particular pair of driver 118 outputs will depend upon the phase relationship between the signal on the EPROM 116 output line associated with that pair and the soft-start pulses 512 appearing at the output of buffer 510.

The frequency of soft-start pulses is higher than the frequency of the control pulses. For example, the frequency of the soft-start pulses 512 may be on the order of 14.4 KHz, whereas the control pulses 122 may have a frequency on the order of 400 Hz. These frequencies are by way of example only and any desired frequencies may be used as long as the frequency of the soft-start pulses is higher than the frequency of the control pulses.

Modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only, and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications which come within the scope of the appended claims is reserved.

Claims

What is claimed is:

1. An inverter system comprising:

inverter switching means having an inverter input for receiving DC and an inverter output, said inverter switching means inverting DC at said inverter input to AC and providing said AC at said inverter output, said inverter switching means including switches having control terminals for controlling conduction of said switches;

control means for supplying switch control pulses, said switch control pulses having a first frequency;

soft-start means for supplying soft-start pulses, said soft-start pulses having a second frequency, said second frequency being substantially constant, said soft-start pulses having a substantially constant duty cycle and substantially constant amplitude, said second frequency being higher than said first frequency; and

pulse control means for supplying only said soft-start pulses and said switch control pulses to said control terminals of said switches, said pulse control means supplying a plurality of said soft-start pulses to said control terminals during a predetermined amount of time at start up and then supplying said switch control pulses to said control terminals thereafter.

2. The inverter system of claim 1 wherein said soft-start means comprises oscillator means for providing oscillator pulses having said second frequency and timing means responsive to said oscillator means for supplying said soft-start pulses to said pulse control means during said predetermined amount of time.

3. The inverter system of claim 2 wherein said oscillator means comprises an oscillator connected to a first monostable multivibrator for supplying said oscillator pulses, and wherein said timing means comprises a second monostable multivibrator and logic gate means, said second monostable multivibrator providing a timing pulse having a length determining said predetermined amount of time, said logic gate means being responsive to said timing pulse and to said oscillator pulses for supplying said soft-start pulses.

4. The inverter system of claim 3 wherein said logic gate means comprises a first AND gate having one input for receiving said oscillator pulses, a second input for receiving said timing pulse, and an output, an OR gate having one input connected to said output of said first AND gate, a second input for receiving an inversion of said timing pulse, and an output, and a second AND gate having one input connected to said output of said OR gate, a second input for receiving a signal indicating start up of said inverter, and output means connected to said pulse control means.

5. The inverter system of claim 4 wherein said inverting switching means comprises a transformer having primary winding means connected to said switches and having secondary winding means for providing said AC.

6. The inverter system of claim 5 wherein said primary winding means comprises first, second and third primary windings and said secondary winding means comprises first, second and third secondary windings, said inverter switching means being arranged to energize said first, second and third primary windings so that three phase AC voltage is induced in said first, second and third secondary windings.

7. The inverter system of claim 4 wherein said inverting switching means comprises first and second transformers having respective primary winding means connected to separate ones of said switches and having respective secondary winding means, said primary winding means of said first transformer inducing a first voltage in said secondary winding means of said first transformer and said primary winding means of said second transformer inducing a second voltage in said secondary winding means of said second transformer, said secondary winding means of said first and second transformers being connected to add said first and second voltages for providing said AC.

8. The inverter system of claim 7 wherein each of said primary winding means comprises first, second and third primary windings and each of said secondary winding means comprises first, second and third secondary windings, said inverter switching means being arranged to energize said first, second and third primary windings of each of said transformers so that three phase AC voltage is induced in said corresponding first, second and third secondary windings.

9. The inverter system of claim 1 wherein said inverting switching means comprises a transformer having primary winding means connected to said switches and having secondary winding means for providing said AC.

10. The inverter system of claim 9 wherein said primary winding means comprises first, second and third primary windings and said secondary winding means comprises first, second and third secondary windings, said inverter switching means being arranged to energize said first, second and third primary windings so that three phase AC voltage is induced in said first, second and third secondary windings.

11. The inverter system of claim 1 wherein said inverting switching means comprises first and second transformers having respective primary winding means connected to separate ones of said switches and having respective secondary winding means, said primary winding means of said first transformer inducing a first voltage in said secondary winding means of said first transformer and said primary winding means of said second transformer inducing a second voltage in said secondary winding means of said second transformer, said secondary winding means of said first and second transformers being connected to add said first and second voltages for providing said AC.

12. The inverter system of claim 11 wherein each of said primary winding means comprises first, second and third primary windings and each of said secondary winding means comprises first, second and third secondary windings, said inverter switching means being arranged to energize said first, second and third primary windings of each of said transformers so that three phase AC voltage is induced in said corresponding first, second and third secondary windings.

13. An excitation circuit for use at start up of an inverter, said inverter receiving first pulses for causing said inverter to invert input DC into output AC, said excitation circuit comprising:

pulses having a frequency greater than said first pulses, said frequency of said second pulses being substantially constant;

a monostable multivibrator for providing a relatively long timing pulse at start up;

pulse control means coupled to said pulse supply means and to said monostable multivibrator and having an output, said pulse control means supplying said second pulses to said output only during said timing pulse; and

pulse selection means for receiving said first and second pulses and for supplying said second pulses to said inverter and then said first pulses thereafter.

14. The excitation circuit of claim 13 wherein said pulse supply means comprises an oscillator and a second monostable coupled to said oscillator for supplying third pulses.

15. The excitation circuit of claim 14 wherein said pulse control means comprises a first AND gate having one input for receiving said third pulses, a second input for receiving said timing pulse, and an output, an OR gate having one input coupled to said output of said first AND gate, a second input for receiving an inversion of said timing pulse, and an output, and a second AND gate having one input coupled to said output of said OR gate, a second input for receiving a signal indicating start up of said inverter, and output means coupled to said pulse selection means.

16. An inverter system comprising:

transformer means having first and second primary winding means and first and second secondary winding means, said first and second secondary winding means being coupled so that voltages induced in said first and second secondary winding means will add;

inverter switches coupled to said first and second primary windings means, said inverter switches for controlling supply of DC to said first and second primary winding means so that corresponding first and second voltages are induced in said first and second secondary winding means, said inverter switches having control terminals for controlling conduction of said switches;

soft-start means for supplying soft-start pulses, said soft-start pulses having a second frequency, said second frequency being higher than said first frequency; and

pulse control means for supplying said soft-start pulses and said switch control pulses to said control terminals of said switches, said pulse control means supplying a plurality of said soft-start pulses to said control terminals at start up and then connecting said switch control pulses to said control terminals thereafter.

17. The inverter system of claim 16 wherein said soft-start means comprises oscillator means for providing oscillator pulses having said second frequency and timing means responsive to said oscillator means for supplying said soft-start pulses to said pulse control means during said predetermined amount of time.

18. The inverter system of claim 17 wherein said oscillator means comprises an oscillator connected to a first monostable multivibrator for supplying said oscillator pulses, and wherein said timing means comprises a second monostable multivibrator and logic gate means, said second monostable multivibrator providing a timing pulse having a length determining said predetermined amount of time, said logic gate means being responsive to said timing pulse and to said oscillator pulses for supplying said soft-start pulses.

19. The inverter system of claim 18 wherein said logic gate means comprises a first AND gate having one input for receiving said oscillator pulses, a second input for receiving said timing pulse, and an output, an OR gate having one input connected to said output of said first AND gate, a second input for receiving an inversion of said timing pulse, and an output, and a second AND gate having one input connected to said output of said OR gate, a second input for receiving a signal indicating start up of said inverter, and output means connected to said pulse control means.